KR20220116473A - Use and method of coating material on edges of decorative panels - Google Patents

Abstract

The present invention relates to the use of a fluoroacrylate polymer for producing a covering (23) or treatment at the edges of a decorative panel (1). The invention also relates to a method for producing decorative panels (1) in which said polymer is used as a covering (23) or treatment.

Description

Use and method of coating material on edges of decorative panels

The present invention relates to the use of a coating material on the edge of a decorative panel, as well as a method for producing a panel such as a floor panel in which such a coating material is used.

In particular, the present invention relates to a panel used, for example, to construct a floating floor covering. Such floor panels are known for example from WO 97/47834 and are preferably milled coupling means fitted together which allow two such floor panels to be coupled together at their respective side edges, without the use of glue. A profiled edge region may be provided on two opposite side edges comprising: Potentially, the coupling means can be implemented with some pre-tensioning, which means that in the coupled state the contours of the coupling means overlap to some extent in such a way that tensions that push the panels towards each other occur. It is interesting that this pre-tensioning prevents the formation of gaps after laying. It can also limit the penetration of dust and moisture. In some cases, the milling quality of the coupling means is insufficient to keep the seam permanently watertight. Also, the susceptibility to water intrusion is increased at the corner points of these panels. At the corners, the profiled edges of adjacent lateral edges intersect, whereby it is possible that the milled coupling means are non-existent or insufficient.

In the case of panels having a moisture-sensitive substrate and/or a top layer, such as a substrate based on MDF or HDF (medium or high-density fibreboard), the penetration of moisture into the seams of the floor covering composed of the panels is for decorative purposes of these panels. It can lead to swelling and/or discoloration that appear disturbing on the surface. Moreover, this swelling of the substrate itself can lead to accelerated wear of the floor surface. Moreover, penetration of moisture into the seams of the floor covering is problematic in itself, even if the substrate or top layer is not moisture sensitive. In this case, water can collect under the floor covering, which can cause mold formation and its associated discomfort.

From WO 2008/078181 it is known to treat the side edges of floor panels with MDF or HDF substrates with water repellent materials comprising fluorinated polymers or copolymers. The substances under discussion are applied to the side edges of the floor panels by so-called vaccumates, for example of the type known from DE 92 02 976 U1. The start and stop of these backcumates at the entry and exit ports of the side edges from the backcumate, respectively, are difficult to fine-tune and may cause the angled points of the related side edges to be insufficiently covered with the related water repellent material.

The main object of the present invention is to provide an alternative coating material for the formation of a water-repellent or water-resistant coating on the edge of a decorative panel, thereby, according to various preferred embodiments, the problems of the method and/or panel from the prior art. Solutions may be provided for one or more of these.

The invention is, inter alia, defined in the appended claims, and relates to the use of a coating material and a method to which such a coating material is applied.

Some preferred embodiments are described below, without limitation.

The use according to the invention is preferably applied, for example, as a treatment for the MDF or HDF (medium or high-density fiberboard) edges of laminate flooring panels in order to obtain a water-repellent or waterproof effect.

The aforementioned coating material is preferably a fluoroacrylate polymer having the formula:

One or more R groups are fluorine atoms and the other R groups are hydrogen atoms. Here, preferably, there are no hydrogen atoms in the R′ group, preferably selected from the list consisting of sodium, potassium, CF ₃ .

The fluoroacrylate polymer preferably has the formula:

Preferably, there are no hydrogen atoms in the R' group, and is preferably selected from the list consisting of sodium, potassium, CF ₃ . Preferably, the R′ group is CF ₃ .

Therefore, it is preferred to use a fluoroacrylate polymer. The acrylate is preferably a perfluorocarbon, meaning that the C-atoms are saturated by F-atoms and no more H-atoms are present. As a result, the highest contact angle and water resistance are achieved.

Preferably, the potential mixture containing the fluoroacrylate polymer should be free of ethyl acetate. Ethyl acetate has a very high flammability (flash point -3°C) and has a known safety hazard.

Preferably, no flammable solvents are present in the mixture containing the fluoroacrylate polymer. This fact has a significant impact on fire safety. Since solvents preferably have a flash point above 55° C., they can no longer be considered highly flammable or even flammable. However, the solvent, preferably at least the isoalkane, remains flammable.

Caution is required during application to ensure that LEL (lower explosive level) concentrations are not reached. This is achieved by extracting at a sufficient flow rate in the application environment.

The mixture also preferably contains a "cosolvent" (glycol ether) which acts as a wetting agent for the fluoroacrylate polymer in wood, or wood-based panels, to penetrate deeper, for example into fibreboard, ie MDF or HDF. and is more readily absorbed, for example, by wood.

Solvents based on isoalkanes and glycols which may be present in the mixture are non-toxic and consist of aliphatic compounds. However, caution is required not to exceed the limits set by law. Because of the low evaporation value, the hazard is virtually non-existent.

The application itself to the edges of the floor panel is initially carried out by means of a transfer technique in which the liquid is first applied to a wheel or roller and then transferred by way of the wheel or roller to the edge of the panel. This application method is similar to that described in WO 2006/038867. The solvent-based or water-based mixture may have a possibly low viscosity such that it is not readily absorbed by the wheel and readily flows from the wheel back to the fluid reservoir. To improve this, an alkyd polymer, which is preferably dissolved in a non-aromatic solvent, is added. These alkyd resins may or may not be urethanes or isocyanates modified to promote water resistance. The advantage is threefold: in addition to the price advantage, alkyds not only provide increased viscosity, but especially in the case of medium or long chain resins, penetration into the wood is less deep and due to its low dispersion it will provide a first barrier. can Resins form an outer film, while fluorine is more likely to provide impregnation protection. Since a relatively thin layer is applied, the coating does not need to be dried to comply with current ecological standards (AgbB, etc.).

Following the delivery application, a spray application may also be applied. The advantage of this application is that higher layer thicknesses can be achieved, which improves water resistance.

In addition to the amount applied, the following parameters are also important for achieving good water-repellent properties:

- Squareness of the panel

- a technique known per se from for example WO'97/47834, ie the contours of the coupling means overlap at two opposite edges of the panel, so that in the coupled state a part of the coupling is bent, and its elastic restoring force is As a result, pre-tensioning between the panels is achieved through the technique of pushing the edges towards each other. Preferably, it relates to elastic bending of a groove lip, for example a lower groove lip, in a tongue-and-groove connection with an interlocking element.

- Milling quality with the edge of the panel finished.

Suitable colorants may be added to the coating to cover the resulting white lines during milling from the melamine layer, for example in the case of laminate panels. These colorants do not affect water resistance. For this purpose, they preferably do not consist of solid particles such as pigments, but rather consist of liquid colorants.

Since the application preferably takes place on a click connection, ie on a mechanical coupling means, UV deterioration of the coating may not occur, which leads to a long service life.

Preferably, the use according to the invention is applied to a decorative panel having a substrate applied with a decorative top layer.

Preferably, the substrate consists mainly of MDF or HDF boards (medium or high density fibreboard), preferably having an average density in excess of 800 kilograms per cubic meter. Preferably, it comprises an HDF board of a type that exhibits a locally higher density on both surfaces, the so-called peak density, which amounts to at least 110% of the average density. In this case, it is clear that the more centrally located HDF material has a density lower than the average density, for example less than 90% of this average density. Preferably, the substrate has a density greater than 900 kilograms per cubic meter at the actual substrate surface. In the case of an HDF board having a peak density of at least 110% of the average density, said lower edge region is preferably deeper than the zone having said peak density, ie preferably a density corresponding to the average density of the relevant board or its It extends into a zone with less than. The presence of a higher density near the surface of the substrate, preferably on that side of the substrate having at least a decorative top layer, results in an increased resistance to the occurrence of effects visible on the surface due to the penetration of moisture into the substrate. do. For example, a higher density zone will have minimal effect on possible swelling effects of the substrate material that can result in raised edges, resulting in accelerated wear of the top surface in the vicinity of those edges.

Preferably, the decorative top layer is a laminate formed on the basis of a melamine resin or other thermosetting resin, and possibly one or more paper sheets. The laminate preferably comprises at least one printed, resin-provided paper sheet, preferably a resin-provided transparent or translucent paper sheet on top. The laminate may further include abrasion resistant particles positioned over the print. Preferably, the laminate is bonded to the substrate material without additional intermediate glue or resin layers on both the actual top surface and the bottom edge region. The laminate is preferably a laminate of the DPL type (“Direct Pressure Laminate”). A special feature of the DPL technology is that the laminate layer, whether or not provided on the decorative paper, for example by means of an impregnation technique, is formed by integrating at least one decorative paper with one or more layers of a synthetic material. The synthetic material is a thermosetting material such as melamine resin. Incorporation includes at least setting or interconnection of the thermosetting composite material. Simultaneously, ie using one and the same pressing operation, this laminate layer is attached to the substrate. For the most common DPL panels, the laminate layer consists of a thermosetting resin-provided decorative paper with a transparent layer applied on top containing a thermosetting resin, also called an overlay. Preferably, a resin layer, for example at least one resin-impregnated paper sheet, is provided on the bottom of the base material during the same pressing operation. It can be used as a balancing layer for any tensile stress in the laminate layer on the top surface, so that a stable and pressed whole can be achieved.

Other possible substrates are, for example, thermoplastic substrates, such as those based on PVC and fillers, or mineral-based substrates, such as portland cement or magnesium oxide, which may also include fillers, for example. It is a base material based on cement.

Other possibilities for a decorative top layer are decorative top layers comprising a printed plastic film, or a print formed directly on a substrate, or comprising a natural material such as wood veneer.

Preferably, said panel is preferably a floor panel of the type that can be used to create a floating flooring system. According to a most preferred embodiment, the floor panel is a laminate floor panel having a decorative top layer of a laminate as described above and a substrate made of MDF or HDF. According to a variant, the floor panel is an LVT, SPC or WPC floor panel, ie a floor panel with a thermoplastic substrate and a decorative top layer with a printed plastic film or print formed directly on the substrate.

Preferably, the panels in question extend perpendicular to each other and have on at least two sides coupling means allowing two such panels to be joined together.

According to a most preferred embodiment, the aforementioned panel is rectangular and elongated.

Preferably, the process of the present invention is used for the production of panels, more particularly floor panels, having a decorative top layer of MDF or HDF substrate and a laminate applied thereto, wherein at least two opposing panel edges the panel has a top surface. A lower edge region is provided, wherein the aforementioned top layer extends continuously from the actual top surface over the surface of the lower edge region to the edge of the top surface. Preferably, the panel obtained by the method of the invention has a lower edge region of the top surface at at least one pair of long edges, preferably in the form of a straight or curved chamfer. Preferably, this comprises a so-called pressed-in chamfer, a chamfer obtained during the same pressing operation applied to realize the DPL laminate layer on the surface of the substrate.

In order to better illustrate the nature of the present invention, by way of example without any limiting features, the following describes some preferred embodiments with reference to the accompanying drawings.

1 shows a floor panel obtained according to the use and method of the present invention;
FIG. 2 shows such a floor panel in a cross-sectional view along the line II-II shown in FIG. 1 ;
Fig. 3 shows the area indicated by F3 in Fig. 2 for a larger scale deformation;
4 shows a variant in a similar view.

1 shows an elongated rectangular floor panel 1 provided with a profiled edge region 6 comprising a mechanical coupling part 7 at two pairs of opposite side edges 2-3 and 4-5 .

2 shows that the coupling part 7 used allows the interlocking of two such floor panels 1 both in the horizontal direction (H) as well as in the vertical direction (V). For interlocking in the vertical direction V, which is the direction perpendicular to the top side 8 of the floor panel 1 , the coupling part 7 shown here mainly consists of a tongue 9 and a groove 10 . is the form The interlocking of the horizontal direction H, ie the direction perpendicular to the above-mentioned vertical direction V, and the direction in the plane of FIG. 2 , in this case, in the lower lip of the groove 10 , the recess 12 and obtained by a locking element in the form of a projection 11 on the underside of the tongue 9 . When coupling these two floor panels 1 , the locking elements 11 - 12 cooperate and prevent the floor panel 1 from moving apart. This is illustrated by the floor panel 1 , shown by the dashed line 13 , where between the tongue 9 and the uncoupled contour of the groove 10 , more specifically of the respective locking element 11 - 12 . It is clearly seen that there may be an overlap 14 between the contours. With this overlap 14 , so-called pretensioning can be achieved when two floor panels are coupled. The concept of pretension is known per se from WO 97/47834. Preferably, the mechanical coupling part 7 used will result in a play-free interlocking of two such floor panels in the aforementioned horizontal direction (H) and vertical direction (V), more preferably the coupling part ( 7) will result in play-free interlocking in all directions in the plane determined by the aforementioned directions (V and H).

It is clear that the floor panel 1 obtained in the context of the present invention can have any shape, such as rectangular, square, hexagonal or similar, as well as provide any coupling parts 7 .

The floor panel 1 shown in Figs. 1 and 2 is a laminate floor panel 1 including a substrate 15, which substrate 15 is entirely made of a wood-based material such as MDF or HDF. Further, the above-described coupling part 7 is made of such a base material 15 and a single piece. The floor panel 1 also comprises a decorative top layer 16 based on a synthetic material. In this case, the decorative top layer 16 is a so-called “DPL” layer, which in this example consists of a decorative layer 17 with a printed motif 18 and a wear-resistant layer 19 applied thereto, such as an overlay . Both the decorative layer 17 and the overlay 19 comprise a layer of paper dipped in resin. Here, the overlay also includes wear-resistant particles such as corundum. On its lower side 20 , the floor panel 1 has a counter layer 21 which also comprises a layer of paper dipped in resin.

At least part of the surface 22 of the profiled edge region 6 is provided with a covering 23 in which a fluoroacrylate polymer is used according to the invention.

FIG. 2 shows here that the covering 23 or the treatment forms a layer or film having a predetermined thickness T. As shown in FIG. In this figure as well as in FIGS. 3 and 4 discussed below, this layer is schematically shown as a layer overlying the surface 22 of the profiled edge region 6 . In practice, it is clear that this layer can penetrate to a greater or lesser extent, or even completely, into the surface region 22 of the associated edge region 6 . Obviously, preferably the thickness T of the layer on top of the surface 22 is minimized, for example, by applying a suitable diluent in order to better absorb the treatment or the covering 23 into the substrate 15 . Be careful to be limited by the thickness (T). In this way, it does not constitute a major obstacle when connecting the associated edge 2-3 to the similar floor panel 1 . It is noted that the thickness T of the film is shown in an exaggerated manner. In practice, the thickness T may or may not be present in the micron range.

3 shows a variant in which the covering 23 covers the limited band below the top edge of the floor panel 1 as well as the transition between the substrate 15 and the decorative top layer 16 . The use of the fluoroacrylate polymer in the band-shaped covering 23 according to the present invention is very useful for traditional laminate floor panels or other floor panels not specifically intended for use in wet rooms. Consequently, the disadvantage of traditional laminate flooring panels is that when cleaning with a damp cloth, moisture is absorbed into the substrate, causing it to swell and permanently pressurize the laminate top layer near the edge of the floor panel. Since a particularly efficient sealing can now be achieved with the active material described above, it is no longer possible for moisture to penetrate into the substrate directly under the laminate top layer, whereby the aforementioned effect is eliminated and otherwise minimized.

It is shown in FIG. 3 that, in the dotted line S, the covering 23 can also extend up to the top surface 8 of the floor panel 1 . In general, the purpose is for the covering 23 to cover at least the transition between the substrate 15 and the top layer 16 .

4 shows a variant in which the profiled edge regions 6 comprise at least a lower edge region 24 or a surface 22A which is formed as a chamfer, in this case as a beveled edge. As shown, a covering 23 may also be provided on the surface 22A of this lower edge region 24 . In the example shown, the decorative top layer 16 extends continuously from the top surface 8 of the floor panel 1 over the surface 22A of the lower edge region 24 .

It is clear that, in the example given in FIGS. 2 to 4 , the undisplayed grooved sides 3-5 of the floor panel 1 are preferably subjected to a similar treatment.

It should also be noted that, generally speaking, an indication means can be integrated into the covering 23 so as to be able to check that it has been applied in a completely covering manner to the desired surface. The display means may be made of a dye or a material that brightens when irradiated with light, for example.

The present invention is not limited to the above-described embodiments, and similar methods for manufacturing a panel can be realized without exceeding the scope of the present invention.

Claims (13)

Use of a fluoroacrylate polymer for achieving a covering (23) or treatment at the side edges of decorative panels (1). The method of claim 1,
The fluoroacrylate polymer has the formula:

have,
The use of a fluoroacrylate polymer, characterized in that one or more R groups are fluorine atoms and the other R groups are hydrogen atoms. The method of claim 1,
The fluoroacrylate has the formula:

have,
Preferably, there are no hydrogen atoms in the R′ group, preferably selected from the list consisting of sodium, potassium, CF ₃ . 4. The method according to any one of claims 1 to 3,
The use of a fluoroacrylate polymer, characterized in that the fluoroacrylate polymer is part of a solvent-based mixture or, alternatively, part of an aqueous-based mixture. 5. The method of claim 4,
The use of a fluoroacrylate polymer, characterized in that the solvent-based mixture has a flash point of at least 35° C., preferably at least 55° C. 6. The method according to claim 4 or 5,
The use of a fluoroacrylate polymer, characterized in that the solvent-based mixture comprises alkanes, preferably isoalkanes, as solvents. 7. The method according to any one of claims 4 to 6,
The use of a fluoroacrylate polymer, characterized in that the solvents and additives in the solvent-based mixture are exclusively of the aliphatic type, or the proportion of the additive and the solvent of the aromatic type in the mixture is less than 1000 ppm, or less than 100 ppm. 8. The method according to any one of claims 1 to 7,
The use of a fluoroacrylate polymer, characterized in that the fluoroacrylate polymer is part of a mixture containing at least a glycol ether or another wetting agent or a surface tension reducing agent. 9. The method according to any one of claims 1 to 8,
The use of a fluoroacrylate polymer, characterized in that the fluoroacrylate polymer is part of a mixture containing at least an alkyd resin, the alkyd resin preferably being a modified urethane or an isocyanate. 10. The method according to any one of claims 1 to 9,
The use of a fluoroacrylate polymer, wherein the fluoroacrylate polymer is part of a mixture containing at least a colorant, preferably a liquid colorant, or at least a colorant free of solid pigments. A method for manufacturing decorative panels, comprising:
The method comprises the step of applying a covering (23) or treatment on at least a part of one side edge of the panels (1), said covering (23) or treatment preferably comprising: A method for manufacturing decorative panels, characterized in that it comprises a fluoroacrylate polymer as defined by claim 10 . 12. The method of claim 11,
The method has at least two opposite side edges (2-3) comprising coupling means (7) allowing the two said panels (1) to be coupled at the associated side edges (2-3) used for the manufacture of panels (1),
In the coupled state, interlocking in the direction V perpendicular to the plane of the coupled panels 1 and/or in the plane of the panels 1 and the coupled side edges 2 - 3) A method for manufacturing decorative panels, characterized in that there is interlocking in the direction (H) perpendicular to . 13. The method according to claim 11 or 12,
The decorative panel (1) is,
- floor panels with a porous or moisture-absorbing substrate 15 , for example MDF, HDF, MgO, cement fiberboard, foamed substrates, for example thermoplastic foamed substrates;
- floor panels with a decorative top layer (16) comprising a print, whereby the decorative top layer (16) is fixed directly or indirectly to an underlying substrate (15) ;
- floor panels with a decorative top layer 16 comprising a wood veneer (thickness < 2.5 mm) or a layer of wood (thickness from 2.5 mm), any wood veneer preferably having a thickness of 0.4 to 0.8 mm floor panels having the decorative top layer; and
- a method for manufacturing decorative panels, characterized in that they are preferably floor panels selected from the list consisting of floor panels for constructing a floating floor covering with an MDF or HDF substrate (15) or a thermoplastic substrate (15) .

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